Concrete form attachment system and assembly

ABSTRACT

An attachment system for use with a concrete form for securing an object within concrete as it cures is described. The attachment system comprises a sacrificial securing element and a tie rod with a first end and a second end. The first end removably engages the sacrificial securing element. Together, the tie rod and the sacrificial securing element jointly secure the object to the inside face of the concrete form. Moreover, the attachment system secures an object by using a single form and can be used when adding siding or exterior designs. In another aspect, a method of securing an object within a concrete wall using a concrete form is described. The method includes the steps of positioning the object in contact with an inner face of the concrete form and positioning a sacrificial securing element proximate the object and amidst a channel. The method also includes pouring cement within the channel and curing the cement to form the concrete wall.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority under 35 U.S.C. §119(e) to a provisional patent application serial no. 60/244,521 filed on Oct. 31, 2000 entitled “Attachment System for Concrete Form having a Sacrificial Nut Plate”. The 60/244,521 patent application is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0002] This invention relates generally to an attachment system for use in constructing a concrete structure and, more particularly, to an attachment system that secures an object to and/or within a concrete structure.

BACKGROUND OF THE INVENTION

[0003] Concrete forming systems are well known and widely used in the construction of diverse concrete structures. When constructing concrete wall structures, a pair of opposing metal form structures is assembled in a face-to-face relation separated by a distance equal to the thickness of the wall to be formed therebetween. Since considerable outward pressure is exerted to push the forms apart by the wet and curing concrete, the pair of form structures should be firmly and rigidly tied together.

[0004] Conventional systems rely on a plurality of tie rods extended between and secured at opposite ends or opposing faces of the form structures. Typically, these systems secure objects to the wall by drilling a hole through both the wall and the forms. Consequently, the tie rods often extend through the constructed wall. Using metal to secure the tie rods can create moisture and thermal transfer. Both moisture and thermal transfers can adversely impact the stability of the constructed wall by resulting in either corrosion and/or heating problems.

[0005] Previous concrete form systems have not utilized a tie rod attachment system that secures an object to the inside of a concrete form using a single side of the concrete wall.

SUMMARY OF THE INVENTION

[0006] In accordance with the purpose of this invention, as embodied and broadly described herein, the invention relates to an attachment system for securing an object within concrete. The attachment system includes a sacrificial securing element and a tie rod having a first end for removably engaging the sacrificial securing element. The tie rod and the sacrificial securing plate jointly secure the object within the concrete.

[0007] In another aspect, this invention relates to an attachment system for use with a concrete form for securing an object within concrete as it cures. The attachment system comprises a sacrificial securing element and a tie rod with a first end and a second end. The first end removably engages the sacrificial securing element. Together, the tie rod and the sacrificial securing element jointly secure the object to the inside face of the concrete form.

[0008] In another aspect, the invention relates to a method of securing an object within a concrete wall using a concrete form. The method includes the steps of positioning the object in contact with an inner face of the concrete form and positioning a sacrificial securing element proximate the object and amidst a channel. The method also includes pouring cement within the channel and curing the cement to form the concrete wall.

[0009] Additional advantages of the invention will be set forth in part in the drawing figures and detailed description, which follow, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the detailed description. It is to be understood that both the foregoing general description and the following drawing figures and detailed description are exemplary and explanatory of preferred embodiments of the invention, and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a perspective view of one embodiment of an attachment system according to the present invention.

[0011]FIGS. 2A and 2B are partial cross-sectional views of a sacrificial bearing plate of this invention illustrating embodiments of the flanges extending therefrom.

[0012]FIG. 2C is a top view of an embodiment of a securing element of this invention.

[0013]FIG. 3 is a cross-sectional view of a concrete form assembly that uses the attachment system of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0014] The present invention may be understood more readily by reference to the following detailed description of the invention and the references to the drawing figures provided therein. It is to be understood that this invention is not limited to the specific components described, as specific components as such may, of course, vary. It is also understood that the terminology used herein is used for the purpose of describing particular embodiments only and is not intended to be limiting. It must also be noted that, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

[0015] Referring now more particularly to the drawings, like numerals in the various figures will be employed to designate like parts. FIG. 1 is a perspective view of an attachment system according to the present invention. The attachment system 6 includes a threaded tie rod 7 that allows easy attachment. The tie rod 7 could be made from steel, titanium, plastic, or some other composite with a diameter of approximately ⅝ inches. In an alternative embodiment, only a portion of the tie rod 7 is threaded, such as the ends. In another embodiment, the tie rod 7 includes a tapered end with a smaller diameter than the other end. For example, the tapered end could have a diameter of 1 inch while the untapered end could have a diameter of 1¼ inches.

[0016] The attachment system 6 also includes a sacrificial securing element 5 illustrated as bearing plate 8 that connects to the tapered end of the tie rod 7. Typically, the sacrificial bearing plate 8 secures objects held by the attachment system 6. Though shown as a generally circular plate, other shapes or forms of the securing elements could include square, rectangular, or a ring as shown in FIG. 2C. Moreover, the sacrificial securing element 5 could be a wing nut, inwardly extending flanges, or some other suitable sacrificial securing element.

[0017] A nut 10 positioned in the center of the sacrificial bearing plate 8 receives a tapered end of the tie rod 7. By threading the rod 7 into the nut 10, the rod 7 secures the bearing plate 8. Securing the bearing plate 8 can position the nut 10 against an object to be secured as illustrated by the electrical box 50 of FIG. 3. Alternatively, the bearing plate 8 could secure the object as illustrated with the foam 60, also shown in FIG. 3.

[0018] The sacrificial bearing plate 8 includes at least one flange 9 a. As shown in FIG. 1, the flanges 9 a and 9 b extend outwardly from side 8 a of the bearing plate 8. Though shown as semi-circular, flanges 9 a and 9 b could be various other shapes such as square, rectangular, or some other suitable shape or configuration. In addition, the number of flanges could be one, three, or more. Moreover, the spacing between the flanges can vary. FIGS. 2A and 2B are partial cross-sectional views of embodiments of the flanges. FIG. 2A illustrates vertically shaped flanges 28. In contrast, FIG. 2B illustrates an L-shaped flange 30.

[0019] When using the attachment system 6 when forming concrete structures, the flange 30 can form windowsills, for example. Preferably, a plurality of parallel, extended flanges project laterally from one side of the bearing plate 8 and are spaced apart by a distance. After the concrete cures, this distance provides resistance against rotational movement during the removal of the rod 7 and concrete form.

[0020] Turning now to FIG. 2C, this figure is a top view of an alternative embodiment of the sacrificial securing element illustrating a circular ring. The sacrificial securing element 17 includes a ring 18, shaft 19, and the central nut 10. The shaft 19 functions similarly to the flanges 9 a and 9 b of FIG. 1 and resists rotational movement of the securing element 17 during the removal of the removable securing element 20. Using the shaft 19 in combination with the ring 18 can resist rotational movement by enabling the cement to surround the shaft 19. As the cement surrounding the shaft 19 cures, the securing element 17 effectively resists rotational movement. Moreover, using the sacrificial securing element 17 can effectively reduce the cost of the invented attachment system. Each sacrificial securing element 17 is replaced after one use because it remains lodged in the concrete wall. Thus reducing the cost of this sacrificial securing element 17 correspondingly reduces the cost for the attachment system 6.

[0021] Finally, the attachment system 6 includes a removable securing element 20 for securing the untapered end of the tie rod 7 to a surface, such as the outside face of a concrete form. Including the removable securing element 20 in the attachment system 6 minimizes displacement of the bearing plate 8. The removable securing element 20 includes a washer 21 and a nut 23 that receive the untapered end of the tie rod 7. Threading the removable securing element 20 attaches it to the tie rod 7. Together, the washer 21 and nut 23 reduce displacement and slippage. For example, the washer 21 and nut 23 can minimize slippage when tightening the removable securing element 20 to the outside face of a concrete form. Using a wing nut 23 enables easy operation of the attachment system 6 even when a substance, such as oil or concrete, lodges in the threads of the tie rod 7.

[0022]FIG. 3 is a cross-sectional view of a concrete form assembly that uses the attachment system 6 when forming a concrete wall. The form assembly 40 includes a pair of oppositely facing forms 42 and 44 defining the channel 46. Pouring concrete into the channel 46 between the forms 42 and 44 results in the concrete wall 48. Using several attachment systems 6 or conventional tie rods that extend along the length of the concrete wall 48 can maintain the spacing of the forms 42 and 44 against the outward force exerted by wet and curing concrete.

[0023] Forms 42 and 44 will not be described in detail, it being understood that the concrete forms are known in the art and made from a variety of materials including metal, wood and other suitable materials. Typically, each form includes a plurality of holes spaced at regular intervals to receive conventional tie rods or attachment systems 6. The holes in the forms 42 and 44 enable positioning of the attachment system 6 at any convenient location along the length of the forms 42 and 44. Several factors could be considered when deciding the position of an attachment system 6, such as the location of an electrical outlet. Consequently, some of the objects that the attachment system 6 can secure include an electrical box 50, foam insulation 60, or some other suitable object. Though FIG. 3 illustrates two attachment systems 6 and no conventional tie rods, the concrete form assembly 40 can include any other suitable combination of attachment systems 6 and conventional tie rods.

[0024] To secure an object using the form assembly 40, the object is positioned proximate one of the forms. For example, the foam insulation 60 is placed adjacent to form 44, while the electrical box 50 is positioned proximate form 42. As the attachment system 6 secures the position of the electrical box 50 and foam insulation 60, the bottom surface 8 a and flanges 9 a and 9 b remain in the channel 46. Hence, pouring the concrete in the channel 46 lodges the sacrificial bearing plate 8 into the concrete wall 48. While FIG. 3 shows operation of the form assembly 40 using the sacrificial bearing plate 8, the form assembly 40 could alternatively include the sacrificial securing element 17 described with reference to FIG. 2C.

[0025] The friction fit of the bearing plate 8 against the electrical box 50 and foam 60 strengthens the position of the structures, distributes the tie rod 7 forces, and increases the resistance of the wall 48 from inward deformation and failure. After the concrete has cured sufficiently to remove the forms 42 and 44, the tie rod 7 is detached by unthreading it from the bearing plate 8. Hence, the sacrificial bearing plate 8 remains lodged in the wall 48 and the rod of the attachment system 6 can be reused with another sacrificial bearing plate 8.

[0026] By lodging the sacrificial securing element in the wall, this element can be used in additional development associated with the wall. For example, using the sacrificial securing element enables securing of additional forms, scaffolding, nail strips, brackets for furring strips, as well as a host of other devices. By securing brackets for furring strips, for example, siding can be added around the concrete wall. In addition, the embedded sacrificial securing element can enable attachment of a grid system used in creating exterior designs. When the sacrificial securing element is no longer needed, the associated hole can be plugged with cement and foam. Hence the sacrificial securing element can be used long after the initial construction of the concrete wall, if desired.

[0027] The invention also includes a method of securing an object to and/or within a concrete structure using a concrete form. The method includes positioning the object in contact with an inner face of the concrete form. A sacrificial securing element is positioned proximate the object and amidst a channel. In another step, the method removably secures the position of the sacrificial securing element. Finally cement is poured within the channel, which forms the concrete wall after curing of the concrete.

[0028] The attachment system and method according to the present invention effectively secures objects to and/or within a concrete wall. The invention uses a sacrificial securing element that remains lodged in the wall even after removal of the concrete forms. This securing element can be used to subsequently add siding or exterior designs. Moreover, the unique design of the attachment system enables securing an object by using a single form.

[0029] Although the invention has been described with respect to a preferred embodiment thereof, it is to be understood that it is not to be so limited since changes and modifications can be made therein which are within the full intended scope of the invention as defined by the appended claims. 

What is claimed is:
 1. An attachment system for use with a concrete form, for securing an object within concrete as it cures, the attachment system comprising: a sacrificial bearing plate; and a tie rod having a first end and a second end, said first end being adapted for removably engaging said sacrificial bearing plate, said tie rod and said sacrificial bearing plate being jointly operative for securing the object to the inside face of the concrete form as the concrete cures.
 2. The attachment system of claim 1 further comprising a removable securing element for securing said second end of said tie rod to an outside face of the concrete form.
 3. The attachment system of claim 2 wherein said removable securing element includes a nut.
 4. The attachment system of claim 3 wherein said nut includes a throughbore for receiving said second end of said tie rod.
 5. The attachment system of claim 1 wherein said sacrificial bearing plate comprises a nut for receiving said first end of said tie rod.
 6. The attachment system of claim 5 wherein said sacrificial bearing plate comprises at least one a flange extending into the concrete.
 7. The attachment system of claim 1 wherein said tie rod is threaded.
 8. The attachment system of claim 1 wherein the object includes an object selected from the group comprises an electrical box or foam insulation.
 9. An attachment system for securing an object within concrete, the attachment system comprising: a sacrificial securing element; and a tie rod having a first end for removably engaging the sacrificial securing element, the tie rod and the sacrificial securing element jointly operative for securing the object within the concrete.
 10. A concrete form assembly for use in constructing a concrete wall comprising the attachment system of claim
 9. 11. The attachment system of claim 9 further comprising a removable securing element for securing a second end of said tie rod to a concrete form.
 12. The attachment system of claim 11 wherein said removable securing element comprises a wing nut and washer.
 13. The attachment system of claim 9 wherein said sacrificial securing element comprises a nut plate.
 14. The attachment system of claim 9 wherein said sacrificial securing element comprises at least one of flange or at least one shaft extending into the concrete wall.
 15. The attachment system of claim 9 wherein said sacrificial securing element comprises a ring.
 16. The attachment system of claim 9 wherein said object includes either an electrical box or foam insulation.
 17. A method of securing an object within concrete wall using a concrete form, comprising the steps of: positioning the object in contact with an inner face of the concrete form; positioning a sacrificial securing element proximate the object and amidst a channel; pouring cement within the channel; and curing the cement to form the concrete wall.
 18. The method of claim 17 wherein the step of removably securing the position of the sacrificial securing element includes using an attachment system.
 19. The method of claim 18 wherein the attachment system comprises a tie rod having a first end for removably engaging said sacrificial securing element, the tie rod and the sacrificial securing element jointly operative for securing the object within the concrete wall.
 20. The method of claim 19 wherein said sacrificial securing element comprises a nut plate or a ring. 